JP2012006379A - Method for generatively manufacturing three-dimensional object with broaching element and method for generating corresponding data set - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for generatively manufacturing a three-dimensional object by which removal of remaining powder in the three-dimensional object is simplified.SOLUTION: (a) Powder material 11 is applied in a layer shape onto a support 5 of a producing apparatus or onto a precoated layer, (b) the powder material 11 is selectively solidified by using energy radiation 8' at a position corresponding to a cross-section of three dimensions object 3 in the layer and (c) the application and the solidification are repeated till the three-dimensional object 3 is completed. The three-dimensional object 3 has at least one cavity 13 opened in an opening 14 in the surface, the powder material 11 extends in the cavity 13 and is solidified to form a broaching member 12 which can be taken out of the cavity via the opening 14.

Description

  The present invention relates to a method for generating a three-dimensional object and a method for generating a corresponding data set.

  Patent Document 1 (DE 199 37 260 B4) discloses a known method and apparatus for generatively producing a three-dimensional object. This method and apparatus comprises: a) a step of applying a powder material to a support of the apparatus or a previously applied layer, and b) energy radiation at a position corresponding to the cross section of the three-dimensional object in the layer. A step of selectively solidifying the powder material, and c) a step of repeating the coating step of a) and the solidification step of b) until the three-dimensional object is completed.

  Patent document 2 (DE 295 06 716 U1) discloses a known post-processing method for producing a three-dimensional object in a generative manner. In this method, a three-dimensional object is blown off with air using an air gun in order to remove residual powder.

German Patent Invention No. 1937260 German utility model No. 29506716

  An object of the present invention is to provide a generative manufacturing method of a three-dimensional object that simplifies the removal of residual powder in the three-dimensional object. This three-dimensional object is achieved by a method comprising the features of claim 1 and a method for generating a data set having the features of claim 10. The dependent claims define further advantageous specific examples of the present invention.

  The three-dimensional object according to the invention has the advantage that it can discharge the residual powder inside without significant burden. For example, an elongated shaped broaching member allows for the release of residual powder in the path of a three-dimensional object or in a somewhat angled cavity, at least to create a guide path. If airflow is applied with or without coarse grains so that each of the channel and the entire cross-section of the cavity is gradually exposed, this guideway allows the flow at the minimum flow rate.

  The broached member is an element of data used when manufacturing a three-dimensional object. The broaching member is arranged so as not to contact the inner wall of the cavity. In a cavity that is in the form of a uniformly extending inner wall path, the broaching member extends at least approximately along the neutral axis of the path. A separate broaching member may be provided for each cavity of the three-dimensional object. Similarly, two members may be arranged in one cavity. That is, the broaching member may be divided at a branch point indicating a point of an angle suitable for broaching, and can be taken out from both of the openings in the cavity.

  The broach member may have an elongated shape, but is not limited to this shape. Each type of geometric shape that is an element of a data set for a three-dimensional object can be used, and a guideway can be exposed. The broached member may have a flat channel cross-sectional strip shape, a corrugated shape, or a spiral shape, or a combination thereof. Thus, residual powder can be released from each of the large angled cavities, passages, or curved passages.

  Further features and objects of the present invention will become apparent from the following description of embodiments based on the accompanying drawings.

1 shows a schematic diagram of an apparatus for producing a three-dimensional object. FIG. 2 shows a cross-sectional view of a three-dimensional object manufactured by the apparatus of FIG.

  FIG. 1 shows a schematic view of an apparatus for manufacturing a three-dimensional object 3 exemplarily embodied as a laser sintering apparatus.

  The laser sintering apparatus includes a frame 1 having an opening at an upper portion thereof and a support body 5 provided therein, and a support body 5 that supports a three-dimensional object 3 to be manufactured and is vertically movable. The frame 1 surrounds the modeling area 6 in the upper part 2. Preferably, the frame 1 and the support 5 form an alternative frame that is removable and replaceable from the laser sintering apparatus. The support 5 is connected to the lift mechanism 4 that vertically moves the support 5 at least below the surface of the modeling region 6 so that the upper side of each layer to be solidified follows the surface of the modeling region 6.

  Furthermore, a coating device 10 for coating a layer of the powder material 11 is provided. As the powder material 11, all laser-sinterable powders can be used. Examples thereof include synthetic powder, metal powder, ceramic powder, foundry sand, and composite material powder. Metal-containing powdered materials, powder materials including any metals and alloys, and mixtures with metal-containing and non-metal-containing elements can also be considered.

  The coating device 10 is moved to a predetermined height above the modeling region 6 so that the layer of the powder material 11 is above the support 5 and above the last solidified layer, respectively. Further, the apparatus includes a laser 7-shaped radiation device that generates laser beams 8 and 8 ′ which are concentrated at an arbitrary position in the modeling region 6 by the deflecting unit 9. Therefore, the laser beams 8 and 8 ′ can selectively solidify the powder material 11 at a position corresponding to the cross section of the three-dimensional object 3 to be manufactured.

  The laser sintering apparatus may include a heating device (not shown) above the modeling region 6 in order to preheat the newly coated powder layer near the processing temperature of the powder material 11 necessary for solidification.

  Reference numeral 100 indicates a housing in which the frame 1, the support 5, and the coating apparatus 10 are arranged. Preferably, the housing 100 has an entrance for introducing the laser beams 8, 8 'in the upper region. Moreover, preferably, the housing | casing 100 is formed airtight and can introduce an inert gas in the inside. Furthermore, the control apparatus 40 is provided in this manufacturing apparatus. The manufacturing apparatus is cooperatively controlled by the control device 40 in order to perform the modeling process and to control the influence of energy by the laser 7. In order to manufacture the three-dimensional object 3, the control device 40 uses a data set in which the shape of the three-dimensional object 3 is defined by CAD data or the like.

  In the operation of the manufacturing apparatus, first, the support 5 is lowered by the lift mechanism 4 until the upper side of the support 5 is below the surface of the modeling region 6 in a desired thickness unit of the first powder layer. . Next, a layer of the first powder material 11 is coated on the support 5 by the coating apparatus 10 and flattened. When a heating device is provided, the overall temperature of the uppermost powder layer 11 can be preheated to a temperature several degrees lower than the processing temperature required for solidification using the heating device. Thereafter, the control device 40 controls the deflecting means 9 so that the deflected laser beams 8, 8 'act selectively on the position of the layer of the powder material 11 to be solidified. Accordingly, the powder material 11 is solidified and / or sintered at those positions, thereby producing a three-dimensional object 3.

  Next, the support 5 is lowered by the lift mechanism 4 in a desired thickness unit of the next layer. The second powder material layer is coated and flattened by the coating apparatus 10 and further selectively solidified by the laser beams 8 and 8 '. These steps are repeated until the desired object 3 is manufactured.

  FIG. 2 shows a cross-sectional view of a three-dimensional object 3 produced by the apparatus of FIG.

  The three-dimensional object 3 has a cavity 13 opened in the opening 14 on the lower surface thereof. During the production of the three-dimensional object 3, the powder material 11 is solidified so as to additionally form a broaching member 12 that extends into the cavity 13 and can be removed from the cavity 13 via the opening 14. In the embodiment shown in FIG. 2, the cavity 13 is also opened in the second opening 14 ′ on the upper surface of the three-dimensional object 3. The broaching member 12 can also be removed from the cavity 13 via the second opening 14 '.

  Thus, the broaching member 12 is not a unique component in the final three-dimensional object 3. After the three-dimensional object 3 is completed by the laser sintering process, the broaching member 12 is taken out from the opening 14 of the cavity 13 and a pilot channel is generated. The guide path simplifies the removal of the residual powder material 11 to be removed from the cavity 13 after the laser sintering process. After the broaching element 12 is removed, fluid is added to the opening 14 and the generated guideway. As a result, the powder material 11 in the cavity 13 is removed, and the entire cross section of the cavity 13 is gradually exposed. For example, the fluid may be pressurized air with or without coarse particles, and is sprayed along the surface of the three-dimensional object 3. Thereby, the powder material 11 is sucked, for example, from the opening 14 by the dynamic pressure similar to that of the Venturi-nozzle. Therefore, the pressurized air is sucked into the cavity 13 through the other opening 14 '. Alternatively, pressurized air may be blown directly into the opening 14. As a result, the residual powder material 11 is discharged from the other opening 14 '.

  The fluid described above is not limited to pressurized air, and may be another gas such as an inert gas, or a liquid such as water or oil.

  In the illustrated embodiment, the broaching member 12 has an elongated shape. However, the invention is not limited to this shape and the broaching element can have a strip shape, a corrugated shape, a helical shape, or other suitable shape. For example, the waveform shape vibrates into a sine wave, a rectangular wave, or a sawtooth waveform.

  The broaching member 12 is preferably bendable if the cross-section of the broaching member 12 is appropriately sized taking into account the powder material used. This is advantageous when the broaching member 12 is removed from the angled cavity. For example, the broaching member 12 can be expanded and contracted when taken out.

  Similarly, it is conceivable to form the broaching member 12 with joints or as a chain consisting of a plurality of chain links.

  The broaching member 12 may be provided with barbs or a pressing member (both not shown) that take in a large amount of powder material 11 when the broaching member 12 is removed.

  In the illustrated embodiment, the broaching member 12 has a gripping member 15 that facilitates gripping the broaching member 12. However, the gripping member 15 may not be provided.

  As can be seen from FIG. 2, the broaching member 12 does not contact the inner wall of the cavity 13. In the illustrated embodiment, the cavity 13 has a uniformly extending inner wall and is in the shape of a passage 13. Preferably, the broaching member 12 extends substantially along the neutral axis of the passage 13. Therefore, an ideal route of the guide route is ensured. However, the path of the broaching member 12 need not necessarily extend along the neutral axis of the passage 13.

  In FIG. 2, a second broaching member 12 'is additionally illustrated. The second broaching member 12 ′ is formed separately from the first broaching member 12 and can be taken out from the third opening 14 ″.

  Although not shown in the above embodiment, the broaching member 12 may have a branch point where the broaching member 12 proceeds to a different branch of the cavity of the three-dimensional object 3. Preferably, the broaching member 12 is removed from an opening that joins the unbranched portion of the broaching member in the three-dimensional object.

  It is also conceivable to form several separate broaching members 12 in one cavity 13 of the three-dimensional object 3. Similarly, it is conceivable that the separated broaching member 12 extends partially to different branches of the cavity 13.

  The present invention also relates to a method for generating a data set of a three-dimensional object 3. The three-dimensional object 3 is manufactured using a generative manufacturing method for the three-dimensional object 3. For example, the data set includes CAD data of the three-dimensional object 3, whereby the laser sintering apparatus produces the three-dimensional object 3. In addition, the laser sintering apparatus executes a manufacturing method. By means of the laser sintering device, the powder material 11 is applied repeatedly and in layers on the support 5 of the device or on the previously applied layer. The powder material 11 is solidified at a position corresponding to the three-dimensional object 3 by the energy radiation 8 '. The three-dimensional object 3 has at least one cavity 13 opened in an opening on its surface.

  The method for generating a data set of a three-dimensional object 3 according to the present invention includes the following steps.

  Initially, a data set defining the dimensions and shape of the completed three-dimensional object is generated in a general manner. For example, these are normal CAD data of the three-dimensional object 3.

  Next, a data set is completed using data defining the dimensions and shape of the broached member 12. The broaching member 12 extends into the cavity 13 and can be removed from the cavity 13 through the opening 14. Thereby, the broaching member 12 is manufactured together with the unique three-dimensional object 3 by a laser sintering apparatus.

  The technical scope of the present invention is not limited to the illustrated embodiments, and further modifications and improvements provided belong to the technical scope of the present invention as defined in the claims.

  For example, the production apparatus of the present invention can be applied not only to laser sintering, but also to all production methods based on powder used for each layer on which a raw material and a powder material are applied. There, the powder is solidified by energy radiation or the like. The energy radiation does not necessarily have to be the laser beam 8 ', but may be, for example, an electron beam or a particle beam. Furthermore, radiation to the entire surface is possible, for example a mask. Instead of energy radiation, an adhesive or a binder that selectively adheres the powder material can be applied to each desired position.

Claims (10)

a) The powder material (11) is applied in layers to the support (5) of the production apparatus or the previously applied layer,
b) selectively solidifying said powder material (11) at a position corresponding to the cross section of the three-dimensional object (3) in the layer;
c) a generative production method of a three-dimensional object (3) comprising repeating the coating and the solidification until the three-dimensional object (3) is completed,
The three-dimensional object (3) has at least one cavity (13) opened in an opening (14) in the surface of the three-dimensional object (3);
The powder material (11) extends into the cavity (13) and is solidified to form a broaching member (12) that can be removed from the cavity through the opening (14). A generative production method of a three-dimensional object (3) using the production apparatus characterized. After the three-dimensional object (3) is completed, the broaching member (12) is taken out from the opening (14) of the cavity (13) to form a guide path,
The manufacturing method according to claim 1, further comprising applying a fluid to the opening (14) and the guide path so that the powder material (11) in the cavity (13) is removed.   The method according to claim 1 or 2, wherein the broaching member (12) has a strip shape, a corrugated shape, a spiral shape, or a combination thereof.   The manufacturing method according to any one of claims 1 to 3, wherein the broaching member (12) has a pressing member or a hook.   The method according to any one of claims 1 to 4, wherein the broaching member (12) has a gripping member (15).   The broaching member (12) preferably does not contact the inner wall of the cavity (13) and has a uniformly extending inner wall in the shape of a passage (13), preferably a neutral axis of the path. The manufacturing method according to claim 1, wherein the manufacturing method extends substantially along the axis.   The cavity (13) opens into at least two openings (14, 14 ') on the surface of the three-dimensional object (3), and the broach from the cavity (13) in both openings (14, 14') The manufacturing method according to claim 1, wherein the processed member can be taken out.   8. The broaching member (12) according to claim 1, wherein the broaching member (12) has a branch point where the broaching member (12) advances to a different branch of the cavity (13) of the three-dimensional object (3). The manufacturing method as described in any one.   A plurality of broaching members (12, 12 ') are formed in one or more cavities (13) in the three-dimensional object (3). The manufacturing method as described. The powder material (11) is repeatedly applied in layers to the support (5) of the production apparatus or the previously applied layer, and the powder material (11) is solidified at a position corresponding to the three-dimensional object (3). A method of generating a data set of a three-dimensional object (3) manufactured by a generative manufacturing method,
Generating a data set defining the shape of the completed three-dimensional object (3) comprising at least one cavity (13) opened in an opening (14) in the surface of the three-dimensional object (3);
Supplementing the data set with data defining the shape of a broaching member (12) extending into the cavity (13) and removable from the cavity (13) through the opening (14) How to create a dataset.

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